TECHNICAL FIELD
[0001] This invention relates to a method for preparing a carbinol-modified organosiloxane,
and more particularly, to a method for efficiently preparing a terminally carbinol-modified
organosiloxane while minimizing formation of side reaction products.
BACKGROUND ART
[0002] Carbinol-modified organosiloxanes are widely used as modifiers for polycarbonate
and polyurethane resins (Patent Documents 1 to 4).
[0003] Among methods for preparing such organosiloxanes in an industrially efficient manner,
for example, Patent Document 5 discloses a method for continuously preparing a carbinol-terminated
diorganopolysiloxane.
[0004] Generally, in the modification of a resin with a modifier, if an organosiloxane in
which carbinol modification has been hampered by side reactions is used as the modifier,
the resin may undergo a decline of molecular weight and eventually lose mechanical
properties.
[0005] The current requirement for resins of further improved performance necessitates minimizing
side reactions during the preparation of carbinol-modified organosiloxanes.
PRIOR ART DOCUMENTS
PATENT DOCUMENTS
SUMMARY OF THE INVENTION
TECHNICAL PROBLEM
[0007] An object of the invention, which has been made under the above-mentioned circumstances,
is to provide a method for efficiently preparing a carbinol-modified organosiloxane
while minimizing formation of side reaction products in the terminal carbinol modification
of organosiloxane.
SOLUTION TO THE PROBLEM
[0008] Making extensive investigations to attain the above object, the inventors have found
that a carbinol-modified organosiloxane having a minimal content of side reaction
products is obtained by continuously reacting an organohydrogensiloxane with a carbinol
compound in the presence of a predetermined amount of a platinum catalyst in a tubular
reactor. The invention is predicated on this finding.
[0009] The invention is defined below.
- 1. A method for preparing a carbinol-modified organosiloxane comprising the steps
of:
- (A) continuously feeding components (a) to (c) to a tubular reactor,
- (a) an organohydrogensiloxane having the following formula (I):

wherein R1 is each independently a C1-C20 monovalent hydrocarbon group and m is an integer of 0 to 500,
- (b) a compound having the following formula (II):
R2-Z-OH (II)
wherein R2 is vinyl or allyl, Z is a divalent hydrocarbon group, at least one hydrogen atom
in the divalent hydrocarbon group may be substituted by halogen or a C1-C20 monovalent hydrocarbon group, and at least one carbon atom in the divalent hydrocarbon
group and the monovalent hydrocarbon group may be substituted by oxygen, nitrogen
or sulfur,
- (c) a platinum catalyst in an amount to give 0.005 ppm by weight to less than 1.0
ppm by weight of platinum metal based on the total weight of components (a) to (c),
- (B) effecting hydrosilylation reaction of components (a) to (c) during passage through
the tubular reactor to form a reaction product, and
- (C) taking out the reaction product.
- 2. The method of 1 wherein step (A) includes mixing components (a) to (c) and then
continuously feeding the mixture to the tubular reactor.
- 3. The method of 1 or 2 wherein component (c) is added in an amount to give 0.005
ppm by weight to 0.2 ppm by weight of platinum metal based on the total weight of
components (a) to (c).
- 4. The method of any one of 1 to 3 wherein component (b) is a compound having the
following formula (III):

wherein X is halogen or a C1-C20 monovalent hydrocarbon group, at least one hydrogen atom in the monovalent hydrocarbon
group may be substituted by halogen, at least one carbon atom in the monovalent hydrocarbon
group may be substituted by oxygen, nitrogen or sulfur, and n is an integer of 0 to
4.
- 5. A carbinol-modified organosiloxane having the following formula (IV):

wherein R is each independently a group having the following formula (V) or (VI),
R1 is each independently a C1-C20 monovalent hydrocarbon group, and m is an integer of 0 to 500,
-(CH2)k-Z-OH (V)
wherein k is 2 or 3, Z is a divalent hydrocarbon group, at least one hydrogen atom
in the divalent hydrocarbon group may be substituted by halogen or a C1-C20 monovalent hydrocarbon group, and at least one carbon atom in the divalent hydrocarbon
group and the monovalent hydrocarbon group may be substituted by oxygen, nitrogen
or sulfur,
-O-Z-R3 (VI)
wherein Z is as defined above, R3 is vinyl, allyl or a terminal group having -(CH2)k-SiR12O-resulting from reaction of Si-H in the following formula (I):

wherein R1 and m are as defined above, with vinyl or allyl, and k is 2 or 3,
groups R being such that a ratio [number of groups having formula (VI)]/[total number
of groups having formulae (V) and (VI)] is less than 0.01.
- 6. The carbinol-modified organosiloxane of 5 wherein R is such that a ratio of [number
of groups having formula (VI)]/[total number of groups having formulae (V) and (VI)]
is up to 0.005.
- 7. The carbinol-modified organosiloxane of 5 or 6, having a platinum content of less
than 0.50 ppm by weight.
- 8. The carbinol-modified organosiloxane of any one of 5 to 7, having a platinum content
of less than 0.20 ppm by weight.
- 9. The carbinol-modified organosiloxane of any one of 5 to 8 wherein Z is a group
having the following formula (VII):

wherein X is halogen or a C
1-C
20 monovalent hydrocarbon group, at least one hydrogen atom in the monovalent hydrocarbon
group may be substituted by halogen, at least one carbon atom in the monovalent hydrocarbon
group may be substituted by oxygen, nitrogen or sulfur, n is an integer of 0 to 4,
and the wavy line designates a point of attachment.
ADVANTAGEOUS EFFECTS OF THE INVENTION
[0010] The preparation method of the invention is successful in efficiently forming a terminally
carbinol-modified organosiloxane with less side reaction products.
[0011] With the inventive preparation method, the amount of platinum used can be reduced
and the purification step can be accordingly simplified. Only a lesser amount of platinum
is left behind, which prevents the resulting carbinol-modified organosiloxane from
coloration due to the residual platinum.
[0012] A terminally carbinol-modified organosiloxane obtained from the inventive preparation
method is useful as a resin modifier because of low contents of side reaction products
and platinum.
DESCRIPTION OF EMBODIMENTS
[0013] Now the invention is described in detail.
[0014] The invention provides a method for preparing a carbinol-modified organosiloxane,
comprising at least the following steps (A) to (C):
step (A) of continuously feeding components (a) to (c) to a tubular reactor,
- (a) an organohydrogensiloxane having the following formula (I):

wherein R1 is each independently a C1-C20 monovalent hydrocarbon group and m is an integer of 0 to 500,
- (b) a compound having the following formula (II):
R2-Z-OH (II)
wherein R2 is vinyl or allyl, Z is a divalent hydrocarbon group, at least one hydrogen atom
in the divalent hydrocarbon group may be substituted by halogen or a C1-C20 monovalent hydrocarbon group, and the divalent hydrocarbon group and the monovalent
hydrocarbon group may be separated by oxygen, nitrogen or sulfur,
- (c) a platinum catalyst in an amount to give 0.005 ppm by weight (ppmw) to less than
1.0 ppmw of platinum metal based on the total weight of components (a) to (c),
step (B) of effecting hydrosilylation reaction of components (a) to (c) during passage
through the tubular reactor, and
step (C) of taking out the reaction product.
(1) Step (A)
[0015] Step (A) is to continuously feed components (a) to (c) to a tubular reactor.
[0016] Component (a) is the organohydrogensiloxane having formula (I) wherein R
1 is each independently a C
1-C
20 monovalent hydrocarbon group.
[0017] The C
1-C
20, preferably C
1-C
10 monovalent hydrocarbon group R
1 may be straight, branched or cyclic, and examples thereof include straight or branched
alkyl groups such as methyl, ethyl, n-propyl, isopropyl, butyl, isobutyl, tert-butyl,
n-pentyl, neopentyl, n-hexyl, and n-octyl; cycloalkyl groups such as cyclopentyl,
cyclohexyl, and cyclooctyl; aryl groups such as phenyl, tolyl, xylyl, and naphthyl;
aralkyl groups such as benzyl, phenylethyl, and phenylpropyl; and substituted forms
of the foregoing groups in which some or all of the hydrogen atoms are substituted
by halogen (e.g. fluorine, bromine and chlorine).
[0018] Of these, R
1 is preferably a C
1-C
6 alkyl or C
6-C
10 aryl group, with methyl and phenyl being more preferred.
[0019] In formula (I), m is an integer of 0 to 500, preferably an integer of 0 to 300, and
more preferably an integer of 30 to 200.
[0020] If m exceeds 500, the resulting carbinol-modified organosiloxane has too high a molecular
weight and can detract from the transparency and mechanical properties of a resin
when used as a resin modifier.
[0021] Component (b) is a carbinol (or phenol) derivative having formula (II). Hydrosilylation
reaction of component (b) with Si-H groups at both ends of component (a) forms a carbinol
(or phenol)-modified organosiloxane.
[0022] In formula (II), R
2 is vinyl or allyl, preferably allyl.
[0023] Z is a divalent hydrocarbon group. The carbon count of the divalent hydrocarbon group
is preferably 1 to 20 carbon atoms, more preferably 1 to 10 carbon atoms, though not
particularly limited.
[0024] The divalent hydrocarbon group may be straight, branched or cyclic, and examples
thereof include straight, branched or cyclic alkylene groups such as methylene, ethylene,
trimethylene, propylene, tetramethylene, pentamethylene, hexamethylene, cyclohexylene,
and octamethylene; arylene groups such as o-phenylene, m-phenylene, p-phenylene, methylphenylene,
ethylphenylene, methoxyphenylene, and naphthylene; and substituted forms of the foregoing
groups in which some or all of the hydrogen atoms are substituted by halogen atoms
(e.g. fluorine, bromine and chlorine), the above C
1-C
20 monovalent hydrocarbon groups or the like. It is noted that some carbon in the divalent
hydrocarbon group and the monovalent hydrocarbon group may be substituted by oxygen,
nitrogen or sulfur.
[0025] Of these, Z is preferably a phenylene group which may be substituted with X, having
the following formula (VII).

Herein the wavy line designates a point of attachment.
[0026] X is halogen or a C
1-C
20 monovalent hydrocarbon group. Examples of the monovalent hydrocarbon group are as
exemplified above for R
1. Some carbon in the monovalent hydrocarbon group may be substituted by oxygen, nitrogen
or sulfur. Examples of the monovalent hydrocarbon group in which some carbon is substituted
by oxygen include C
1-C
5 alkoxy groups such as methoxy, ethoxy, isopropoxy, n-butoxy, and tert-butoxy.
[0027] X is preferably a C
1-C
5 alkyl or C
1-C
5 alkoxy group, more preferably methyl or methoxy.
[0028] The subscript n is an integer of 0 to 4, preferably 0 or 1, and more preferably 0.
[0029] Therefore, compounds having the following formula (III) are preferred as component
(b).

Herein X and n are as defined above.
[0030] Examples of component (b) which is preferably used herein include those of the following
formulae, but are not limited thereto. Of these, (b-1), (b-2), (b-9; p=6), and (b-10;
q=1, r=0) are especially preferred.

Herein p, q and r are each independently an integer of 0 to 50, preferably 0 to 10.
[0031] Component (c) is a platinum catalyst for promoting hydrosilylation. Examples of the
platinum catalyst used herein include well-known catalysts such as platinum black,
platinic chloride, chloroplatinic acid, the reaction products of chloroplatinic acid
with monohydric alcohols, complexes of chloroplatinic acid with olefins, and platinum
bisacetoacetate.
[0032] In step (A), components (a) and (b) are continuously fed to a tubular reactor in
such a ratio that [moles of alkenyl groups in component (b)]/[moles of Si-H groups
in component (a)] preferably ranges from 1.00 to 2.00, more preferably from 1.05 to
1.50, and even more preferably 1.02 to 1.10. If the ratio exceeds 2.00, sometimes
unreacted component (b) must be removed or the cost of the reactant may be increased,
with a loss of production efficiency. A ratio of less than 1.00 may increase the probability
that side reaction occurs at the terminal reactive sites of the organosiloxane.
[0033] Component (c) is added in such an amount as to give 0.005 ppmw to less than 1.0 ppmw,
preferably 0.005 to 0.50 ppmw, more preferably 0.005 to 0.20 ppmw, and even more preferably
0.010 to 0.10 ppmw of platinum metal based on the total weight of components (a) to
(c). An amount of less than 0.005 ppmw of platinum causes a problem to the progress
of hydrosilylation reaction. An amount of 1.00 ppmw or more increases the probability
that side reaction occurs at the terminal reactive sites of the organosiloxane.
[0034] In step (A), components (a) to (c) may be continuously fed to a tubular reactor separately
via feed tubes, or some or all of components (a) to (c) may be premixed, for example,
in a stirred tank and then fed continuously to a tubular reactor.
[0035] Notably, the tubular reactor used herein is not particularly limited and may be suitably
selected from well-known flow reactors which allow for reaction of components (a)
to (c) during passage therethrough.
[0036] In step (A), the temperature at which components (a) to (c) are fed is not particularly
limited. The temperature is preferably 0°C to 150°C, more preferably 10°C to 100°C,
and even more preferably 20°C to 80°C for smooth progress of reaction in step (B).
[0037] In addition to components (a) to (c), a solvent may be added in step (A).
[0038] Examples of the solvent include alkanes such as pentane, hexane, octane, decane,
isododecane, cyclopentane, cyclohexane, methylcyclohexane, and ethylcyclohexane; aromatic
hydrocarbons such as benzene, toluene, xylene, and ethylbenzene; ethers such as diethyl
ether, ethyl propyl ether, glyme, and diglyme; and alcohols such as ethanol, 1-propanol,
and 2-propanol.
(2) Step (B)
[0039] Step (B) is to effect hydrosilylation reaction of component (a) with component (b)
while passing components (a) to (c) through the tubular reactor.
[0040] The temperature in the tubular reactor in this step, though not particularly limited,
is preferably 20°C to 180°C, more preferably 40°C to 150°C, and even more preferably
50°C to 120°C for enhancing the reaction efficiency and suppressing side reactions.
[0041] Notably, the total time of steps (A) and (B), though not particularly limited, is
preferably 1 to 60 minutes, more preferably 3 to 45 minutes, and even more preferably
5 to 30 minutes, from the aspect of production efficiency.
(3) Step (C)
[0042] Step (C) is to take out the reaction product obtained in step (B).
[0043] The take-out rate of the reaction product depends on the feed rate in step (A) and
is not particularly limited. From the aspect of efficient production, the rate is
preferably at least 100 kg/h, more preferably at least 200 kg/h, and even more preferably
at least 300 kg/h.
[0044] The taken-out reaction product may be used as such, but if necessary, may be purified
by well-known means prior to use.
[0045] The inventive preparation method described above is efficient to produce a terminally
carbinol-modified organosiloxane with minimal contents of side reaction products and
platinum.
[0046] The carbinol-modified organosiloxane obtained from the inventive preparation method
has the following formula (IV).

Herein R
1 and m are as defined above.
[0047] In formula (IV), R is each independently a group having the following formula (V)
or (VI).
-(CH
2)
k-Z-OH (V)
-O-Z-R
3 (VI)
[0048] In formula (V), k indicative of the number of methylene groups derived from vinyl
or allyl represented by R
2 in the compound of formula (II) used as the reactant is 2 or 3.
[0049] In formula (VI), R
3 is vinyl or allyl derived from R
2 in the compound of formula (II) used as the reactant, or a terminal group having
-(CH
2)
k-SiR
12O- resulting from reaction of Si-H in the organohydrogensiloxane of formula (I) with
vinyl or allyl in the carbinol compound of formula (II) used as the reactants, wherein
k is 2 or 3.
[0050] In formulae (V) and (VI), Z is as defined above. Likewise, Z is preferably a group
having the above formula (VII). More preferably, Z is selected from those of the following
formulae which are derived from the above-described compounds preferred as component
(b), even more preferably (Z-1), (Z-2), (Z-8; p=6), and (Z-9; q=1, r=0), but not limited
thereto.

Herein the wavy line designates a point of attachment.
[0051] The carbinol-modified organosiloxane of the invention is characterized by R which
is such that a ratio of [number of groups having formula (VI)]/[total number of groups
having formulae (V) and (VI)] is less than 0.01. If the ratio is 0.01 or more, the
carbinol-modified organosiloxane contains more side reaction products and when used
as a resin modifier, may invite a decline of the molecular weight of the resin, detracting
from its mechanical properties.
[0052] Specifically, the preferred ratio of [number of groups having formula (VI)]/[total
number of groups having formulae (V) and (VI)] is up to 0.005.
[0053] It is noted that the ratio used herein is computed in
29Si-NMR spectroscopy from the integrated value of signals assigned to Si of -O-Si(R
1)
2-CH
2- structure derived from formula (V) and the integrated value of signals assigned
to Si of -O-Si(R
1)
2-O-Z- structure derived from formula (VI).
[0054] The content of platinum in the inventive carbinol-modified organosiloxane is preferably
less than 0.50 ppmw, more preferably less than 0.20 ppmw. A platinum content within
the range ensures to prevent coloration due to platinum of the carbinol-modified organosiloxane
even when a purification step is omitted and coloration of a resin which is modified
with the carbinol-modified organosiloxane.
[0055] Because of such a minimal impurity content, the carbinol-modified organosiloxanes
of the invention are useful as resin modifiers.
[0056] The resin to be modified therewith is not particularly limited, and examples thereof
include polycarbonate, polyurethane, polyester, and epoxy resins.
EXAMPLES
[0057] Examples and Comparative Examples are given below for further illustrating the invention
although the invention is not limited thereto.
[0058] As used herein, the term "terminal impurity ratio" refers to a ratio [number of groups
having formula (VI)]/[total number of groups having formulae (V) and (VI)], which
was computed from the integrated value of signals assigned to Si of -O-Si(R
1)
2-CH
2-structure derived from formula (V) and the integrated value of signals assigned to
the Si of -O-Si(R
1)
2-O-Z- structure derived from formula (VI) in the
29Si-NMR spectrum of a carbinol-modified organosiloxane.
Example 1
[0059] While heating at 50°C, an organohydrogenpolysiloxane having the following average
formula (1) at 380 kg/h, 2-allylphenol at 19 kg/h, and a platinum catalyst (i.e. toluene
solution of 1,3-divinyl-1,1,3,3-tetramethyldisiloxane complex of neutralized chloroplatinic
acid) were each fed to a 150-L tubular reactor at a rate to provide 0.02 ppmw of platinum
metal based on the mixture in the system. The mixture was passed through the tubular
reactor at 80°C over 20 minutes for reaction. Thereafter the reaction product was
continuously taken out into a storage tank. The carbinol-modified organosiloxane thus
obtained had a terminal impurity ratio of 0.0010.

Example 2
[0060] The same procedure as in Example 1 was repeated except that the concentration of
the platinum catalyst was changed to 0.10 ppmw of platinum metal. The resulting carbinol-modified
organosiloxane had a terminal impurity ratio of 0.0025.
Example 3
[0061] The same procedure as in Example 1 was repeated except that the concentration of
the platinum catalyst was changed to 0.48 ppmw of platinum metal. The resulting carbinol-modified
organosiloxane had a terminal impurity ratio of 0.005.
Example 4
[0062] While heating at 50°C, 380 kg of an organohydrogenpolysiloxane having the average
formula (1), 19 kg of 2-allylphenol, and an amount to provide 0.75 ppmw of platinum
metal based on the mixture in the system of a platinum catalyst (i.e. toluene solution
of 1,3-divinyl-1,1,3,3-tetramethyldisiloxane complex of neutralized chloroplatinic
acid) were stirred and mixed for 10 minutes in a stirred tank. The resulting mixture
was passed through a 150-L tubular reactor at 80°C and 400 kg/h over 20 minutes for
reaction. Thereafter the reaction product was continuously taken out into a storage
tank. The resulting carbinol-modified organosiloxane had a terminal impurity ratio
of 0.009.
Example 5
[0063] The same procedure as in Example 1 was repeated except that 23 kg/h of eugenol was
fed instead of 19 kg/h of 2-allylphenol and the concentration of the platinum catalyst
was changed to 0.90 ppmw of platinum metal. The resulting carbinol-modified organosiloxane
had a terminal impurity ratio of 0.008.
Comparative Example 1
[0064] The same procedure as in Example 4 was repeated except that the concentration of
the platinum catalyst was changed to 1.0 ppmw of platinum metal. The resulting carbinol-modified
organosiloxane had a terminal impurity ratio of 0.010.
Comparative Example 2
[0065] The same procedure as in Example 1 was repeated except that the concentration of
the platinum catalyst was changed to 1.5 ppmw of platinum metal. The resulting carbinol-modified
organosiloxane had a terminal impurity ratio of 0.021.
1. A method for preparing a carbinol-modified organosiloxane, comprising the steps of:
(A) continuously feeding components (a) to (c) to a tubular reactor:
(a) organohydrogensiloxane having the following formula (I):

wherein each R1 independently is a C1-C20 monovalent hydrocarbon group and m is an integer of 0 to 500,
(b) compound having the following formula (II):
R2-Z-OH (II)
wherein R2 is vinyl or allyl, Z is a divalent hydrocarbon group, one or more hydrogen atoms
in the divalent hydrocarbon group may be replaced by halogen or a C1-C20 monovalent hydrocarbon group, and one or more carbon atoms in the divalent hydrocarbon
group and the monovalent hydrocarbon group may be replaced by oxygen, nitrogen or
sulfur,
(c) platinum catalyst, in an amount to give from 0.005 ppm by weight to less than
1.0 ppm by weight of platinum metal based on the total weight of components (a) to
(c);
(B) effecting hydrosilylation reaction of components (a) to (c) during passage through
the tubular reactor to form a reaction product, and
(C) taking out the reaction product.
2. A method of claim 1 wherein step (A) includes mixing components (a) to (c) and then
continuously feeding the mixture to the tubular reactor.
3. A method of claim 1 or 2 wherein component (c) is added in an amount to give from
0.005 ppm by weight to 0.2 ppm by weight of platinum metal based on the total weight
of components (a) to (c).
4. A method of any one of claims 1 to 3 wherein component (b) is a compound having the
following formula (III):

wherein X is halogen or a C
1-C
20 monovalent hydrocarbon group, one or more hydrogen atoms in the monovalent hydrocarbon
group may be replaced by halogen, one or more carbon atoms in the monovalent hydrocarbon
group may be replaced by oxygen, nitrogen or sulfur, and n is an integer of 0 to 4.
5. A carbinol-modified organosiloxane having the following formula (IV):

wherein
each R independently is a group having the following formula (V) or (VI),
each R1 independently is a C1-C20 monovalent hydrocarbon group, and m is an integer of 0 to 500:
-(CH2)k-Z-OH (V)
wherein k is 2 or 3, Z is a divalent hydrocarbon group, one or more hydrogen atoms
in the divalent hydrocarbon group may be replaced by halogen or a C1-C20 monovalent hydrocarbon group, and one or more carbon atoms in the divalent hydrocarbon
group and the monovalent hydrocarbon group may be replaced by oxygen, nitrogen or
sulfur,
-O-Z-R3 (VI)
wherein Z is as defined above, R3 is vinyl, allyl or a terminal group having -(CH2)k-SiR12O- resulting from reaction of Si-H in the following formula (I):

wherein R1 and m are as defined above, with vinyl or allyl, and k is 2 or 3;
groups R being such that the ratio [number of groups having formula (VI)]/[total number
of groups having formulae (V) and (VI)] is less than 0.01.
6. Carbinol-modified organosiloxane of claim 5 wherein R is such that a ratio of [number
of groups having formula (VI)]/[total number of groups having formulae (V) and (VI)]
is up to 0.005.
7. Carbinol-modified organosiloxane of claim 5 or 6, having a platinum content of less
than 0.50 ppm by weight.
8. Carbinol-modified organosiloxane of any one of claims 5 to 7, having a platinum content
of less than 0.20 ppm by weight.
9. Carbinol-modified organosiloxane of any one of claims 5 to 8 wherein Z is a group
having the following formula (VII):

wherein X is halogen or a C
1-C
20 monovalent hydrocarbon group, one or more hydrogen atoms in the monovalent hydrocarbon
group may be replaced by halogen, one or more carbon atoms in the monovalent hydrocarbon
group may be replaced by oxygen, nitrogen or sulfur, n is an integer of 0 to 4, and
the wavy line designates a point of attachment.